U.S. patent application number 14/079163 was filed with the patent office on 2014-03-13 for automated cartridge detection for a plasma arc cutting system.
The applicant listed for this patent is Hypertherm, Inc.. Invention is credited to Erik Brine, Clayton Gould, Brett A. Hansen, Michael Hoffa, Stephen M. Liebold, Junsong Mao, Jesse A. Roberts, E. Michael Shipulski, Peter J. Twarog.
Application Number | 20140069895 14/079163 |
Document ID | / |
Family ID | 50235846 |
Filed Date | 2014-03-13 |
United States Patent
Application |
20140069895 |
Kind Code |
A1 |
Brine; Erik ; et
al. |
March 13, 2014 |
AUTOMATED CARTRIDGE DETECTION FOR A PLASMA ARC CUTTING SYSTEM
Abstract
The invention features methods and apparatuses for establishing
operational settings of a plasma arc cutting system automatically
using replaceable cartridges. A replaceable cartridge for use with
a plasma arc cutting system includes a housing, a connection
mechanism for coupling the housing to a plasma arc torch, an arc
constrictor connected to the housing, an arc emitter connected to
the housing, and an identification mechanism disposed relative to
the housing and configured to communicate information to a reader
of the plasma arc cutting system and automatically set at least one
operating parameter of the plasma arc cutting system.
Inventors: |
Brine; Erik; (Hanover,
NH) ; Roberts; Jesse A.; (Cornish, NH) ; Mao;
Junsong; (Hanover, NH) ; Hoffa; Michael;
(Lebanon, NH) ; Gould; Clayton; (Orford, NH)
; Twarog; Peter J.; (West Lebanon, NH) ;
Shipulski; E. Michael; (Etna, NH) ; Liebold; Stephen
M.; (Grantham, NH) ; Hansen; Brett A.;
(Mapleton, UT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hypertherm, Inc. |
Hanover |
NH |
US |
|
|
Family ID: |
50235846 |
Appl. No.: |
14/079163 |
Filed: |
November 13, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14075692 |
Nov 8, 2013 |
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14079163 |
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13838919 |
Mar 15, 2013 |
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14075692 |
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13560059 |
Jul 27, 2012 |
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13838919 |
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13439259 |
Apr 4, 2012 |
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13560059 |
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13560059 |
Jul 27, 2012 |
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14075692 |
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13439259 |
Apr 4, 2012 |
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13560059 |
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Current U.S.
Class: |
219/121.44 ;
219/121.39 |
Current CPC
Class: |
H05H 2001/3494 20130101;
H05H 2001/3473 20130101; B23K 10/00 20130101; B23K 10/006 20130101;
H05H 1/34 20130101 |
Class at
Publication: |
219/121.44 ;
219/121.39 |
International
Class: |
B23K 10/00 20060101
B23K010/00 |
Claims
1. A replaceable cartridge for use with a plasma arc cutting
system, the cartridge comprising: a housing; a connection mechanism
for coupling the housing to a plasma arc torch; an arc constrictor
connected to the housing; an arc emitter connected to the housing;
and an identification mechanism disposed relative to the housing
and configured to communicate information to a reader of the plasma
arc cutting system and automatically set at least one operating
parameter of the plasma arc cutting system.
2. The cartridge of claim 1 wherein the identification mechanism is
a radio frequency identification (RFID) mechanism.
3. The cartridge of claim 1 wherein the identification mechanism is
a spring.
4. The cartridge of claim 1 wherein the identification mechanism is
based on a dimension of an opening of the arc constrictor.
5. The cartridge of claim 1 wherein the at least one operating
parameter includes at least one of a cutting current, a pilot arc
current, a plasma gas flow or a shield gas flow.
6. The cartridge of claim 5 wherein the at least one operating
parameter is further adjusted at a specified time during a cutting
operation.
7. The cartridge of claim 1 wherein the information comprises at
least one operating parameter for the plasma arc cutting
system.
8. The cartridge of claim 1 wherein the information denotes a
cartridge type of the cartridge.
9. The cartridge of claim 8 wherein the cartridge type corresponds
to a cutting persona of the plasma arc cutting system.
10. The cartridge of claim 1 wherein the information enables
multiple operating parameters of the plasma arc cutting system to
be set automatically.
11. The cartridge of claim 1, further comprising a shield.
12. The cartridge of claim 1, further comprising a swirling feature
or a swirl ring.
13. The cartridge of claim 1, further comprising a retaining
cap.
14. The cartridge of claim 8, further comprising an exterior
surface with a visual indicia corresponding to the cartridge
type.
15. The cartridge of claim 14 wherein the visual indicia is a
color.
16. The cartridge of claim 8 wherein the cartridge type corresponds
to at least one of a workpiece thickness, a current output or a
cutting process type.
17. A method for operating a plasma arc cutting system, the method
comprising: installing a cartridge in a plasma arc cutting torch,
the cartridge comprising an arc constrictor, an arc emitter and an
identification mechanism; communicating information between the
identification mechanism and a reader of the plasma arc cutting
system; and setting at least one operating parameter of the plasma
arc cutting system based on the communicated information.
18. The method of claim 17 wherein the identification mechanism is
a RFID mechanism.
19. The method of claim 17 wherein the identification mechanism is
a spring.
20. The method of claim 17 wherein the identification mechanism is
based on a dimension of an opening of the arc constrictor.
21. The method of claim 17 wherein the information comprises at
least one operating parameter for the plasma arc cutting
system.
22. The method of claim 17 wherein the information denotes a
cartridge type of the cartridge.
23. The method of claim 17 wherein the cartridge type corresponds
to a cutting persona of the plasma arc cutting system.
24. The method of claim 17 wherein setting at least one operating
parameter of the plasma arc cutting system further comprises
correlating the information with at least one operating parameter
of the plasma arc cutting system via a lookup table.
25. The method of claim 17 wherein the at least one operating
parameter includes at least one of a cutting current, a pilot arc
current, a plasma gas flow or a shield gas flow.
26. The method of claim 17 wherein the plasma arc cutting system
sets multiple operating parameters based on a particular
combination of consumable components of the cartridge.
27. The method of claim 16 further comprising: installing a
different cartridge in the plasma arc torch, the different
cartridge comprising a different arc constrictor, a different arc
emitter, and a different identification mechanism; communicating
different information between the different identification
mechanism and a reader of the plasma arc cutting system; and
setting at least one different operating parameter of the plasma
arc cutting system based on the communicated different
information.
28. A plasma arc cutting system comprising: a power supply for
supplying a cutting current; a plasma arc cutting torch in
electrical communication with the power supply; a detection
mechanism; a cartridge comprising an arc emitter, an arc
constrictor, and an identification mechanism for providing
information to the plasma arc cutting system via communication
between the identification mechanism and the detection mechanism;
and a means for setting at least one operating parameter of the
plasma arc cutting system based on the information communicated
between the identification mechanism and the detection
mechanism.
29. The plasma arc cutting system of claim 28 wherein the
identification mechanism is a RFID device.
30. The plasma arc cutting system of claim 28 wherein the
information communicated between the identification mechanism and
the detection mechanism comprises at least one operating parameter
of the plasma arc cutting system.
31. The plasma arc cutting system of claim 30 wherein the at least
one operating parameter includes at least one of a cutting current,
a pilot arc current, a plasma gas flow or a shield gas flow.
32. The plasma arc cutting system of claim 28 wherein the
information communicated between the identification mechanism and
the detection mechanism denotes a cartridge type of the
cartridge.
33. The plasma arc cutting system of claim 32 wherein the cartridge
type corresponds to a cutting persona of the plasma arc cutting
system.
34. The plasma arc cutting system of claim 28 wherein the
information communicated between the identification mechanism and
the detection mechanism comprises or is correlated with a workpiece
thickness.
35. The plasma arc cutting system of claim 28 wherein the
information is communicated to the power supply.
36. The plasma arc cutting system of claim 28 wherein the means for
setting at least one operating parameter of the plasma arc cutting
system comprises the power supply.
37. The plasma arc cutting system of claim 28 wherein the plasma
arc cutting system establishes multiple operating parameters system
based on a particular combination of consumable components of the
cartridge.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Ser. No.
14/075,692, filed Nov. 8, 2013 and titled "Systems, Methods, and
Devices for Transmitting Information to Thermal Processing
Systems," which is a continuation-in-part of U.S. Ser. No.
13/838,919, filed Mar. 15, 2013 and titled "Systems, Methods, and
Devices for Transmitting Information to Thermal Processing
Systems," which is a continuation-in-part of U.S. Ser. No.
13/560,059, filed Jul. 27, 2012 and titled "Optimization and
Control of Material Processing Using a Thermal Processing Torch,"
which is a continuation-in-part of U.S. Ser. No. 13/439,259, filed
Apr. 4, 2012 and titled "Optimization and Control of Material
Processing Using a Thermal Processing Torch." This application is
also a continuation-in-part of U.S. Ser. No. 13/949,364, filed Jul.
24, 2013 and titled "Plasma Arc Cutting System and Persona
Selection Process." The contents of all of these applications are
hereby incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] The invention relates generally to the field of plasma arc
cutting systems and processes. More specifically, the invention
relates to methods and apparatuses for simplifying cutting tasks by
automatically establishing cutting parameters of plasma arc cutting
systems using consumable cartridges.
BACKGROUND
[0003] Plasma arc torches are widely used in the cutting and
marking of materials. A plasma torch generally includes an arc
emitter (e.g. an electrode) and an arc constrictor (e.g. a nozzle)
having a central exit orifice mounted within a torch body,
electrical connections, passages for cooling, and passages for arc
control fluids (e.g., plasma gas). The torch produces a plasma arc,
a constricted ionized jet of a gas with high temperature and high
momentum. Gases used in the torch can be non-reactive (e.g., argon
or nitrogen) or reactive (e.g., oxygen or air). During operation, a
pilot arc is first generated between the arc emitter (cathode) and
the arc constrictor (anode). Generation of the pilot arc can be by
means of a high frequency, high voltage signal coupled to a DC
power supply and the torch or by means of any of a variety of
contact starting methods.
[0004] Known plasma cutting systems include a large array of
consumables for use with different cutting currents and/or
operating modes. The large number of consumable options can confuse
users and create the possibility of using incorrect consumables.
The large number of consumable options can also cause torch setup
time to be lengthy and can make it difficult to transition between
cutting processes that require different arrangements of
consumables. Furthermore, even after the appropriate consumable
components are selected, the power supply must be configured with
cutting parameters (e.g. values for cutting current, gas flow rate
and/or operating mode) that are appropriate for the consumables
chosen.
SUMMARY OF THE INVENTION
[0005] The present invention addresses the unmet need for a plasma
arc cutting system that simplifies the consumable selection process
through the use of cartridges including consumables appropriate for
a particular cutting task. The present invention also addresses the
unmet need for a system that automatically establishes appropriate
cutting parameters for the cutting task based upon the cartridge
installed.
[0006] The present invention relates to systems and methods for
establishing in a plasma are cutting system, through installation
of a consumable cartridge in a plasma arc cutting torch, at least
one cutting parameter for the plasma arc cutting system (e.g. a
cutting current, a gas pressure or gas flow rate, and/or an
operational mode for the plasma arc cutting system). The present
invention, in one detailed embodiment, enables appropriate cutting
parameters for the plasma are cutting system to be set with minimal
action by the system operator (e.g., through installation of a
cartridge). A cartridge has a housing, a connection mechanism for
coupling the cartridge to a plasma arc torch, and components
including at least an arc constrictor (e.g. a nozzle) and an arc
emitter (e.g. an electrode), and optionally including a swirl ring
or swirling feature, a shield, and/or a retaining cap. The
cartridge also has an identification mechanism including
information used to configure the plasma arc cutting system for a
particular cutting task (e.g. a wireless identification mechanism
such as a radio frequency identification (RFID) tag). The plasma
arc cutting system has a reader (e.g. a RFID reader) for reading
the information and permitting the plasma arc cutting system to be
configured with appropriate cutting parameters based on the
information read.
[0007] In one aspect, the invention features a replaceable
cartridge for use with a plasma arc cutting system. The cartridge
includes a housing. The cartridge includes a connection mechanism
for coupling the housing to a plasma arc torch. The cartridge
includes an arc constrictor connected to the housing. The cartridge
includes an arc emitter connected to the housing. The cartridge
includes an identification mechanism disposed relative to the
housing. The identification mechanism is configured to communicate
information to a reader of the plasma arc cutting system and
automatically set at least one operating parameter of the plasma
arc cutting system.
[0008] In some embodiments, the identification mechanism is a radio
frequency identification (RFID) mechanism. In some embodiments, the
identification mechanism is a spring. In some embodiments, the
identification mechanism is based on a dimension of an opening of
the arc constrictor. In some embodiments, the at least one
operating parameter includes at least one of a cutting current, a
pilot arc current, a plasma gas flow or a shield gas flow. In some
embodiments, the at least one operating parameter is further
adjusted at a specified time during a cutting operation.
[0009] In some embodiments, the information comprises at least one
operating parameter for the plasma arc cutting system. In some
embodiments, the information denotes a cartridge type of the
cartridge. In some embodiments, the cartridge type corresponds to a
cutting persona of the plasma arc cutting system. In some
embodiments, the information enables multiple operating parameters
of the plasma arc cutting system to be set automatically.
[0010] In some embodiments, the cartridge includes a shield. In
some embodiments, the cartridge includes a swirling feature or a
swirl ring. In some embodiments, the cartridge includes a retaining
cap. In some embodiments, the cartridge includes an exterior
surface with a visual indicia corresponding to the cartridge type.
In some embodiments, the visual indicia is a color. In some
embodiments, the cartridge type corresponds to at least one of a
workpiece thickness, a current output or a cutting process
type.
[0011] In another aspect, the invention features a method for
operating a plasma arc cutting system. The method includes
installing a cartridge in a plasma arc cutting torch. The cartridge
includes an arc constrictor, an arc emitter and an identification
mechanism. The method also includes communicating information
between the identification mechanism and a reader of the plasma arc
cutting system. The method also includes setting at least one
operating parameter of the plasma arc cutting system based on the
communicated information.
[0012] In some embodiments, the identification mechanism is a RFID
mechanism. In some embodiments, the identification mechanism is a
spring. In some embodiments, the identification mechanism is based
on a dimension of an opening of the arc constrictor. In some
embodiments, the information comprises at least one operating
parameter for the plasma arc cutting system. In some embodiments,
the information denotes a cartridge type of the cartridge. In some
embodiments, the cartridge type corresponds to a cutting persona of
the plasma arc cutting system.
[0013] In some embodiments, setting at least one operating
parameter of the plasma arc cutting system further comprises
correlating the information with at least one operating parameter
of the plasma arc cutting system via a lookup table. In some
embodiments, the at least one operating parameter includes at least
one of a cutting current, a pilot arc current, a plasma gas flow or
a shield gas flow. In some embodiments, the plasma arc cutting
system sets multiple operating parameters based on a particular
combination of consumable components of the cartridge.
[0014] In some embodiments, the method includes installing a
different cartridge in the plasma arc torch. The different
cartridge includes a different arc constrictor, a different arc
emitter, and a different identification mechanism. In some
embodiments, the method includes communicating different
information between the different identification mechanism and a
reader of the plasma arc cutting system. In some embodiments, the
method includes setting at least one different operating parameter
of the plasma arc cutting system based on the communicated
different information.
[0015] In another aspect, the invention features a plasma arc
cutting system. The plasma arc cutting system includes a power
supply for supplying a cutting current. The plasma arc cutting
system also includes a plasma arc cutting torch in electrical
communication with the power supply. The plasma arc cutting system
also includes a detection mechanism. The plasma arc cutting system
also includes a cartridge comprising an arc emitter, an arc
constrictor, and an identification mechanism for providing
information to the plasma arc cutting system via communication
between the identification mechanism and the detection mechanism.
The cartridge also includes a means for setting at least one
operating parameter of the plasma arc cutting system based on the
information communicated between the identification mechanism and
the detection mechanism.
[0016] In some embodiments, the identification mechanism is a RFID
device. In some embodiments, the information communicated between
the identification mechanism and the detection mechanism comprises
at least one operating parameter of the plasma arc cutting system.
In some embodiments, the at least one operating parameter includes
at least one of a cutting current, a pilot arc current, a plasma
gas flow or a shield gas flow. In some embodiments, the information
communicated between the identification mechanism and the detection
mechanism denotes a cartridge type of the cartridge. In some
embodiments, the cartridge type corresponds to a cutting persona of
the plasma arc cutting system. In some embodiments, the information
communicated between the identification mechanism and the detection
mechanism comprises or is correlated with a workpiece thickness. In
some embodiments, the information is communicated to the power
supply. In some embodiments, the means for setting at least one
operating parameter of the plasma arc cutting system includes the
power supply. In some embodiments, the plasma arc cutting system
establishes multiple operating parameters system based on a
particular combination of consumable components of the
cartridge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The foregoing discussion will be understood more readily
from the following detailed description of the invention when taken
in conjunction with the accompanying drawings.
[0018] FIGS. 1A-1B are cross-sectional illustrations of cartridges
for a plasma arc cutting system, according to an illustrative
embodiment of the invention.
[0019] FIG. 2 is a schematic of a plasma arc cutting system,
according to an illustrative embodiment of the invention.
[0020] FIGS. 3A-3C are illustrations of exterior views of
cartridges for a plasma arc cutting system, according to an
illustrative embodiment of the invention.
[0021] FIG. 4 is a flow diagram of a method of detecting a
cartridge in a plasma arc cutting torch of a plasma arc cutting
system and setting cutting parameters for a plasma arc cutting
system, according to an illustrative embodiment of the
invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0022] FIGS. 1A-1B are cross-sectional illustrations of cartridges
100, 150 for a plasma arc cutting system (e.g. plasma arc cutting
system 200 as shown below in FIG. 2), according to an illustrative
embodiment of the invention. FIG. 1A shows a cartridge 100 that
includes a housing 105, a arc constrictor 110, an arc emitter 115,
and an identification mechanism 120. The arc constrictor 110, the
arc emitter 115, and/or the identification mechanism 120 can be
disposed within the housing 105. The cartridge 100 can have a
connection mechanism 125 for coupling the cartridge 100 to a plasma
arc torch (e.g. plasma arc torch 210 as shown below in FIG. 2).
FIG. 1B shows a cartridge 150 that includes a housing 135, an arc
constrictor 160, an arc emitter 165, and an identification
mechanism 170.
[0023] In some embodiments the cartridge 150 includes one or more
of the following additional components: a shield 175; a swirling
feature 180; and/or a retaining cap (not shown). In some
embodiments, the arc constrictor 110, 160 includes a nozzle. In
some embodiments the arc emitter 115, 165 includes an electrode. In
some embodiments the geometry of an orifice of the arc constrictor
110, 160 and/or the geometry of the swirling feature 180 is
optimized for a particular cutting or gouging process. In some
embodiments a hafnium emitter of the arc emitter 115, 165 can be
optimized for a specific cutting or gouging process. In some
embodiments, the housing 105 includes any component that holds the
cartridge 100, 150 together, e.g. a nozzle body, swirl ring or
separate element. In some embodiments, the connection mechanism 125
is a magnet, a thread, a lip, a latch, or any other mechanism
capable of attaching the cartridge 150 to a torch (not shown). In
some embodiments, the connection mechanism 125 is a retaining
cap.
[0024] The identification mechanism 120, 170 includes information
that can be communicated to a reader of a plasma arc cutting system
(e.g. reader 205 as shown below in FIG. 2). The plasma arc cutting
system then can use the information to automatically set at least
one operating parameter of the plasma arc cutting system, as
described below in FIG. 2.
[0025] FIG. 2 is a schematic of a plasma arc cutting system 200,
according to an illustrative embodiment of the invention. The
plasma arc cutting system 200 includes a cartridge 100, a plasma
arc torch 210 and a plasma power supply 215. The plasma arc torch
210 is in electrical communication with the plasma power supply 215
via electrical connection 220. The plasma arc torch 210 includes a
detection mechanism 205 configured to read information provided by
identification mechanism 120.
[0026] When the cartridge 100 is installed in the plasma arc torch
210, the detection mechanism 205 reads the information contained in
the identification mechanism 205 and passes the information to the
plasma power supply 215. In some embodiments, the detection
mechanism 205 sends a signal to the plasma power supply 215, e.g.
via electrical connection 220. In some embodiments the detection
mechanism 205 sends a signal to the power supply wirelessly. The
plasma power supply 215 then configures at least one operating
parameter of the plasma arc cutting system 200 based on the
information read. For example, the plasma power supply 215 can
configure the operating current, the gas pressure, current controls
(e.g. continuous pilot arc), and/or gas controls (e.g. gas ramping)
based on the information read. The system is thus configured
automatically without the need for further action by the
operator.
[0027] In some embodiments, the identification mechanism 120
includes information that identifies the type of cartridge 100
installed. The cartridge type can be correlated with a certain
cutting task for which (i) a particular combination of consumables
contained in the cartridge 100 is best suited, and/or (ii)
particular plasma system settings are best suited. For example, for
the task of cutting fine features in sheet metal, it would be
appropriate to use a cartridge containing a relatively small arc
constrictor orifice with features capable of imparting a high
swirling gas strength that configured the plasma arc cutting system
200 with a lower cutting current appropriate to the arc constrictor
orifice size and a moderate gas flow. As another example, for the
task of gouging a thick, heavy plate of steel, it would be
appropriate to use a cartridge containing a relatively large arc
constrictor orifice with features capable of imparting a low
swirling gas strength that configured the plasma arc cutting system
200 with a higher cutting current appropriate to the arc
constrictor orifice size and a large gas flow to adequately remove
the molten steel.
[0028] In some embodiments, the information stored by
identification mechanism 120 denotes a cartridge type of the
cartridge 100. The plasma arc cutting system 200 can use the
cartridge type to select appropriate plasma system cutting
parameters using a lookup table stored in memory of the plasma
power supply 215. For example, if the plasma arc cutting system 200
receives information that cartridge type A is installed, it can use
the lookup table to determine that cartridge type A is to be used
with a specific cutting current, gas flow rate and/or cutting mode
and configure the plasma arc cutting system 200 accordingly. On the
other hand, if the plasma arc cutting system 200 receives
information that cartridge type B is installed, it can use the
lookup table to configure the plasma arc cutting system 200 with a
different set of system parameters. In some embodiments, the
identification mechanism 120 stores operational parameters for the
plasma arc cutting system 200. For example, the identification
mechanism can include information comprising specific values for a
cutting current, a pilot arc current, a plasma gas flow rate, a
shield gas flow rate, and/or cutting mode, or other plasma system
parameters. The plasma arc cutting system 200 can then use this
information set the specified values. In some embodiments, the
identification mechanism 120 can store historical data or
performance characteristics of the cartridge. For example, the
identification mechanism 120 can include information comprising the
number of start cycles, the number of arc-hours, the arc voltage or
other data or performance characteristics.
[0029] In some embodiments, the identification mechanism 120 is a
RFID tag. The RFID tag can store information in the foam of digital
data. The detection mechanism 205 can be a RFID reader capable of
reading the digital data. In some embodiments, the identification
mechanism 120 is a physical feature of the cartridge. For example,
a keyed type feature on the cartridge can be detected by the plasma
arc torch 210. In some embodiments, the identification mechanism
120 is a spring that can be identified according to a spring
constant (k). In some embodiments the information of the
identification mechanism 120 is based on a voltage change, a
blowback pressure, or another feature capable of differentiating
multiple consumable cartridges. One of ordinary skill in the art
would understand that the information in the identification
mechanism can be encoded in a variety of physical forms and
interpreted by a variety of corresponding readers suitable for use
with a plasma arc cutting system.
[0030] In some embodiments, the plasma power supply 215 is a power
printed circuit board ("PCB") that can comprise most of the power
components. In some embodiments, the plasma power supply 215
includes a controller, e.g. a microcontroller, a central processing
unit ("CPU") controller, a digital signal processor ("DSP")
controller, or any other type of controller that is capable of
controlling the applicable plasma system settings. In some
embodiments, the plasma power supply 215 is controlled by a remote
controller, for example, a computer numeric controller ("CNC").
[0031] Using the current invention, an operator of the plasma arc
cutting system 200 needs only to select and install a consumable
cartridge 100 based on the specific cutting job desired. System
controls can be simplified or removed entirely from the plasma arc
cutting system 200, as the operator does not need to configure the
power supply settings. Thus, setup time can be greatly reduced.
Table 1 shows test results for a novice user for the selection and
installation of individual consumables known in the art compared to
the selection and installation of a consumable cartridge for
specific cutting processes. As shown, the time taken to select the
correct consumables for the specific job was substantially shorter
using the automated consumable cartridge.
TABLE-US-00001 TABLE 1 User Task Time User 1 Install individual
mechanized cutting consumables 11:50 User 1 Install mechanized
cutting cartridge 1:13 User 2 Install individual hand cutting
consumables 8:00 User 2 Install hand cutting cartridge 2:07
[0032] FIGS. 3A-3C are illustrations of exterior views of
cartridges 300, 310, 320, 330, 340, 350, 360 for a plasma arc
cutting system (e.g. plasma arc cutting system 200 as shown above
in FIG. 2), according to an illustrative embodiment of the
invention. FIG. 3A shows a cartridge 300 including a housing 305.
In some embodiments the cartridges are provided with a visual
indicia of the cut to be performed. In some embodiments the
cartridges are color coded or labeled with another intuitive
indicator of the cut to be performed (e.g. an icon). In some
embodiments, cartridges having consumable sets that encompass a
range of currents and type of cutting processes can be provided for
selection by an operator. In some embodiments the cartridges 300,
310, 320, 330, 340, 350, 360 include an additional retaining
cap.
[0033] In some embodiments, in addition to being optimized for a
particular cutting task, a cartridge may be optimized for a
particular thickness of a given workpiece material. For example,
FIGS. 3B-3C each show a set of three consumable cartridges that are
optimized for a specific cutting task and are optimized for
different workpiece thicknesses. FIG. 3B shows a cartridge set 302
that is intended for fine cutting of mild steel. The cartridge 310
is optimized for cutting 1/4 inch steel; the cartridge 320 is
optimized for cutting 1/2 inch steel; the cartridge 330 is
optimized for cutting 1 inch steel. FIG. 3C shows a cartridge set
304 that is intended for rough cutting of mild steel. The cartridge
340 is optimized for cutting 1/4 inch steel; the cartridge 350 is
optimized for cutting 1/2 inch steel; the cartridge 360 is
optimized for cutting 1 inch steel. For example, for each set of
consumable cartridges an arc constrictor (e.g. nozzle) orifice may
be sized to cut 1/4 inch steel with a cutting current of 60 Amps;
sized to cut 1/2 inch steel with a cutting current of 80 Amps;
and/or sized to cut 1 inch steel with a cutting current of 100
Amps.
[0034] In some embodiments the consumables cartridges can be
designed for each "cutting persona" as described in application
Ser. No. 13/949,364, filed on Jul. 24, 2013, the contents of which
are incorporated herein by reference. A "cutting persona" is a set
of parameters for a plasma arc cutting system that are customized
for a particular kind of cut. For example, one user may want to cut
as fast as possible and sacrifice consumable life. For this type of
cut, a cutting persona that establishes a high current and gas flow
can be desirable. Another user, such as one who is using a computer
numeric controller ("CNC")-controlled table mounted system, may
want to select a cutting persona optimized for long life or fine
cutting. For this type of cut, a cutting persona that establishes a
low current and/or gas flow rate can be desirable.
[0035] FIG. 4 is a flow diagram of a method 400 of detecting a
cartridge in a plasma arc cutting torch of a plasma arc cutting
system and setting cutting parameters for a plasma arc cutting
system, according to an illustrative embodiment of the invention.
In a first step 410, a cartridge comprising an arc constrictor, an
arc emitter and an identification mechanism is installed in a
plasma arc cutting torch. In a second step 420, information is
communicated between the identification mechanism and a reader of
the plasma arc cutting torch. In a third step 430, at least one
operating parameter of a plasma arc cutting system is set based on
the communicated information.
[0036] While the invention has been particularly shown and
described with reference to specific preferred embodiments, it
should be understood by those skilled in the art that various
changes in form and detail may be made therein without departing
from the spirit and scope of the invention as defined by the
following claims.
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